Welding process 1. The initial cost of the gas welding equipment is affordable. We'll begin with a brief history of related welding processes, in order to present Oxy-fuel welding in context. This cylinder has a regulator with two pressure gauges. Control valves – Both the oxygen and the fuel gas cylinders have their own control valves. The different techniques of oxy-acetylene gas welding are forward gas welding, backward gas welding, and vertical gas welding. Gas welding can be done with or without using a filler material. A harsh forceful flame will cause the molten weld pool to be blown away, while too soft a flame will not be stable near the point of application. Gas welding is usually used for thin sheets welding, like automobile bodies, and the initial cost of the equipment is low and affordable. The welder can adjust the action of the gas flame on the surface of the weld metal by producing a soft, harsh, or violent reaction (by varying the flow of acetylene and oxygen). Gas welding is not popular for commercial use or thick plate welding since welding quality is inferior compared to other types of welding like arc welding. Acetylene is the commonly used fuel gas, and when correct proportions of oxygen and acetylene are mixed in a gas welding torch, you will get a hot flame of around 3200º C. You can vary the proportion of acetylene and oxygen to get the desired type of flame. By following the proper procedures, most steels can be successfully welded. A special oxy propane torch is usually used, which is much easier to light and less likely to blow out than when using oxyacetylene torches. These hoses then lead to the torch where they are attached to create the mixture needed … Oxy-fuel welding, more commonly known as oxyacetylene welding, or gas welding, is used for gas welding and gas cutting. Oxy Fuel welding is a very traditional type of welding, relying on a torch to weld the metals. This lever (for oxygen) does not exist on the gas welding torch. The gas cylinders should be stored with their protective caps on when not in use. A: No, oxy-fuel goggles do not protect your eyes from the intense ultraviolet radiation (UV) produced by the welding arc. Preheat flames are used to raise the surface or edge of the steel to approximately 1800°F (bright red color). Oxy-fuel torches, the materials, construction, safety, performance, test procedures, and marking of which are addressed in CGA E-5-2017 – Oxy-Fuel Torch Standard – Sixth Edition, function to convey and control fuel and oxygen in a safe manner. Oxy-fuel welding (commonly called oxyacetylene welding, oxy welding, or gas welding in the U.S.) and oxy-fuel cutting are processes that use fuel gases and oxygen to weld and cut metals, respectively. Oxy-fuel welding and cutting. Oxyfuel gas welding is a process that joins metals by combustion of a fuel gas, oxygen, and air mixed in a nozzle and directed at the work surface (5). The mixing of the gases (oxygen and acetylene) happens in the welding torch. [8] This process is also great for these applications [9]: Manual rough severing; Automated precision contour cutting; Scrap cutting; Once a welder has the equipment for oxy-fuel cutting, he or she can use it for other processes … Each gas is contained in its own cylinder and combined through the use of separate hoses leading from regulators attached to the top of the cylinders. The toppling of gas cylinders can be very dangerous since they are stored at high pressure, and a damaged regulating valve (due to toppling) may allow the gas out at high pressure. The chemical reaction between acetylene and oxygen is exothermic in nature. The gas welding torch is designed to accommodate different sizes of copper nozzles (swan neck type) that allow the proper intensity of the flame to be used. Gas welding is suitable and economical for the welding of pipes used for different applications. These techniques are very highly skilled and are less frequently used than the conventional leftward technique. Once the flame is on the workpiece, the high temperature causes the metal to melt and form a weld pool, and at this point, the metal can be made to fuse together with or without adding the filler metal. Inspect oxy-fuel apparatus for oil, grease, or damaged parts. The welding torch has the mixer chamber at one end and a nozzle at the other end. The Little Story of the Underwater Cutting. The gas oxygen and acetylene are stored in high-pressure cylinders and have pressure regulators to control the outflow of the gas. As the steel is oxidized and blown away to form a cavity, the preheat and oxygen … Oxy-fuel welding process is a welding techniques utilizing a compressed mixture of high energy density fuel and oxygen to generate a flame capable of elevating the temperature of the material to be welded. There are two pressure gauges on each cylinder. French engineers Edmond Fouché and Charles Picard became the first to develop oxygen-acetylene welding in 1903. It comprises oxygen and acetylene gases stored under pressure in steel cylinders. The cylinders and hoses should have distinct colors to differentiate them. The fumes generated in this type of welding originate from the base metal, filler metal, and fluxes. The cutting efficiency of the oxy-gasoline flame is equivalent or sometimes better than the oxy-acetylene flame. There are of course practical limits as to the type of flame which can be used for welding. Backward gas welding (also called rightward gas welding) – This is similar to forward welding, and the only difference is you will start doing the welding from your left and move towards the right. And this welding process is still very popular today, mainly because it does not require much equipment, and does not require power. There is no need for filler material or pressure to create the weld. The flame reaches a temperature of 3200ºC (approximately) which is sufficient to melt steel and other metals. However, for nearly half a century prior and half a century since, the common oxy-fuel torch has been a significant mainstay in the aluminum joining process. Gas welding is used in welding and joining the sheet metal parts of an aircraft. Fuel gas cylinder (red color) -The fuel gas cylinder is made of thick gauge steel and is completely sealed to prevent leakage of the compressed fuel gas stored inside the cylinder. Oxy-acetylene is the typical combination used in gas welding and is generally chosen for general cutting and welding work including work to repair rips and tears in metal. Gas welding is more suitable for the repair of grey cast iron defects when compared to arc welding. All carbon-containing steels can be oxidized and hence can be cut using a gas cutting torch. Pressure gauges – There are two pressure gauges on each cylinder (oxygen and acetylene). Sewalem Gezie. If fuel gas were to leak from the unit, smoking could provide ignition and cause a fire or an explosion. The oxygen cylinder is made of thick gauge steel to withstand the pressure. You should complete the welding by slowly retracting the flame from the weld joint, allowing it sufficient time to harden without oxidation. The acetylene cylinder and the hose connecting the acetylene cylinder and the welding torch are red. Where arc welding utilizes electricity to create a super-heated arc, torch welding (also known as gas welding and oxy-fuel welding) uses a gas mixture ignited through a torch to melt metal pieces. A variety of lenses are used depending on the type of welding or cutting that needs to be … You can hold the welding torch and the filler rod at suitable and convenient angles. This kind of welding is commonly called oxy acetylene welding or gas welding in the U.S. In this article, we will be discussing the following topics: what is gas welding and how it is done, gas welding machine and its parts, fuel gasses used in gas welding, the difference between the gas welding torch and the gas cutting torch, advantages and limitations of gas welding, application, and safety considerations. The gas flame and molten metal emit radiation, and eye protection is very important. Gas welding finds its application in many industries, and many of the general applications are listed below. Welding in the overhead and vertical locations usually are slow compared to horizontal locations. Among these four welding techniques, oxyacetylene welding is the most prominent technique adopted for the purpose of welding … OXY-ACETYLENE WELDING It is the common method of gas welding. Gas welding is not suitable for welding tough steels. Oxy-propane does not produce a high temperature like oxyacetylene, and hence it is normally not used for welding. Care must be taken during all welding processes … The flame trap prevents flames generated by a 'flashback' from reaching the cylinders; principal causes of flashbacks are the failure to purge the hoses and overheating of the blowpipe nozzle. Filler material with flux can be used, and the flux helps prevent oxidation. 33 001 gas welding: Where welding is required to meet AS 1554 General Purpose or equivalent codes, work health and safety (WHS) regulations and/or licensing requirements MEM05055 Weld using oxy fuel gas welding process should also be selected. When mixed together in correct proportions within a hand-held torch or blowpipe, a relatively hot flame is produced with a temperature of about 3,200 deg.C. The gas welding torch is used for gas welding and is typically carried out by burning an equal volume of the fuel gas (acetylene) and oxygen. Welding is generally carried out using the neutral flame setting which has equal quantities of oxygen and acetylene. Propane is cheaper than acetylene and is easily available; hence, oxy-propane is used for cutting scrap. The heliarc (GTAW) was discovered in November of 1942, and by 1946, together with wire-feed (GMAW), helped pioneer the application of new exotic, materials vital to supersonic flight. In the neutral flame, the acetylene gas is completely burned in the oxygen and the surrounding air. Moreover, the welder has a clear view of the weldpool and can work in complete freedom of movement. Different parts of the gas welding equipment are: Oxygen cylinder (green color) – This cylinder contains the oxygen stored under pressure which is required for combustion. Three are three different types of flames such as neutral/natural, oxidizing, and carburizing. B. Other gases important in welding—nitrogen, carbon dioxide and argon—are also made using this process. Ag100% Cu100% 500 700 … Gas welding equipment is very compact and has high portability, the whole equipment fits on a trolley, and you can easily take it to the location required. Always wear your safety gear such as goggles, shoes, an apron, a safety helmet, and hand gloves. Oxy-propane is preferred for the heating and bending process. A container ship is a cargo. Unlike other welding methods, gas welding does not need electricity. The construction of the gas welding torch has two needle valves enabling the operator to fine-tune (adjust) the flow of acetylene and oxygen into the mixing chamber (for delivery of acetylene and oxygen in an equal ratio). The goggles or face shield use special lenses to protect the eyes form light damage. By … The action of the oxyacetylene flame on the surface of the material to be welded can be adjusted to produce a soft, harsh or violent reaction by varying the gas flows. By Francis Hermans. It produces a flame of temperature 3200ºC (approximately), and this temperature is sufficient to melt the steel workpieces and fuse them together into a strong joint. The hose connecting the oxygen cylinder and the welding torch is green, and that connecting the acetylene cylinder and the welding torch is red. The cylinder has a regulator with two pressure gauges. Each fuel gas has its characteristics; some fuel gas may burn to reach high temperatures while others may not. There must be sufficient firefighting equipment in the area of gas welding or gas cutting. Oxyacetylene welding, commonly referred to as gas welding, is a process which relies on combustion of oxygen and acetylene. The tip of the inner cone is the hottest part, and this is where the acetylene and oxygen combine and burn. A few simple precautions can prevent most fires and help minimize damage in the event a fire does occur. Due to hydrogen embrittlement, hydrogen is not used for welding steel and ferrous metals. Oxy-Acetylene welding 101 is part one of Ron Covell's four part welding series, which will give an overview of the most popular cutting and welding processes Practice fire prevention techniques whenever oxy-fuel operations are in progress. Other fuel gases like propane, hydrogen, and natural gas can be used for welding lower melting point metals like nonferrous metals, brazing, and silver soldering. The gas welding fumes are not suitable for human health, and the area of gas welding should have a sound ventilation system. The complete set of gas welding equipment consists of oxygen and fuel gas stored in individual cylinders, two pressure regulators and two pressure hoses (one for each cylinder), and a welding torch. Pure oxygen was used instead of ordinary air to increase the flame temperature. Oxygen can also be made by electrolysis of water, but for industrial quantities this is not cost-effective due to the expense of the electricity needed. Learn vocabulary, terms, and more with flashcards, games, and other study tools. AN INTRODUCTION TO OXY/ACETYLENE WELDING AND CUTTNG. Hydrogen is preferred for underwater welding or cutting. Color code – The hoses and gas cylinders used in gas welding are color-coded for easy identification. Arc welding is far more common in today’s welding applications, and accordingly, the welding processes performed by multi-process welding machines all belong to the arc welding family. The principal techniques employed in oxyacetylene welding are leftward, rightward and all-positional rightward. If you are gas welding zinc-coated sheets, the fumes can be very harmful. Acetylene at high pressure can be dangerous. A wire brush is used to clean the weld area before and after welding, and a chipping hammer is used to chip off the flux coating. Forward gas welding (also called leftward gas welding) – You, as a gas welder, holds the welding torch in your right hand, filler rod in your left hand, and do the welding starting from the right and moving towards the left. Hydrogen – Oxy-hydrogen flame is suitable for welding and cutting aluminum. Insider’s Guide to Gas Metal Arc Welding (GMAW/MIG), Intermediate Bearing Alignment Checks Using the Blue Contact Method, Top 15 Largest Container Shipping Companies in the World, Insider’s Guide to Gas Tungsten Arc Welding (GTAW / TIG), Insider’s Guide to Shielded Metal Arc Welding (SMAW/MMA), Image Quality Indicators (IQIs) or Penetrameters of Radiography Testing. Definitions given in the Standards include: BS499: Part 1 1991 Glossary for welding, brazing, and thermal cutting. However, acetylene is not stable for underwater welding or cutting. The chemical action of the oxyacetylene flame can be adjusted by changing the ratio of the volume of oxygen to acetylene. You might hear this type of welding referred to as “gas welding.” Gas welding is used almost exclusively for welding thin metal sections. Oxidizing flame – An excess oxygen added to the neutral flame creates an oxidizing type of flame. You can use gas welding equipment, for gas cutting, simply by using a different torch. A standard oxyacetylene torch can be used for oxy-propane; however, it is not recommended. Gas welding filler material does not have dedicated flux coating (like in arc welding). The acetylene and oxygen mixture exit from the nozzle to ignite (the welder uses a lighter). A mixture of fuel gas (normally acetylene) and oxygen undergoes combustion. AIRCRAFT WELDING INTRODUCTION. Do not undertake gas welding or gas cutting in any area where flammable items or goods are stored, specifically highly inflammable substances like oil, gas, gasoline, and other flammable items like wood, paper, etc. The oxy-acetylene welding process combines oxygen and acetylene gas to provide a high temperature flame for welding. Acetylene is the popular fuel gas used in gas welding due to its favorable flame characteristics and high temperature. What Is Oxy-Fuel Cutting Used For? Oxy … The flame trap is a safety device and prevents a flame generated by a ‘flashback’ from reaching the gas cylinder. Pure oxygen was used instead of ordinary air to increase the flame temperature. Before you remove the regulator from the cylinder valve, close the cylinder valve and release the gas left out in the regulator. You can get a temperature of 2000ºC for hydrogen mixed with air at atmospheric pressure and 2800ºC when hydrogen is mixed with pure oxygen in the ratio of 2:1. In this process, a flame is applied to heat the steel to a higher temperature and at the time pure oxygen is applied in a continuous stream and it will create the needed weld. Other fuel gases used are gasoline, hydrogen, propane (LPG), etc. This process … A welding helmet with the proper shaded lens must be used whenever welding. Vertical welding – In this type of welding, you will hold the welding torch in your right hand, filler rod in your left hand, and the welding progresses from the bottom towards the top. When it comes to welding thin gauge sheets like car body parts, gas welding is more suitable than other welding methods. The goggles and/or face shield protect the eyes from sparks and flying hot metal particles. The most commonly used fuel gas is acetylene, and many people use the phrase oxy-acetylene welding in place of gas welding. The filler rod moves ahead of the flame. There is a relationship between the thickness of the metal to be welded, nozzle size, and the welding speed. The defect area can be ground off with a handheld rough grinder, preheated to about 600ºC using gas welding, and then gas welded using a cast iron rod to build up the area. One pressure gauge indicates the pressure of the gas inside the cylinder, and the other pressure gauge indicates the pressure of the gas in the hose. Oil and grease may ignite spontaneously, when in contact with oxygen. This cutting nozzle has an outer ring of holes through which the oxyacetylene gas flows and a hole at the center through which additional oxygen flows. The maximum temperature reached in gas welding is much less compared to arc welding. Gas welding is not suitable for welding thick sections due to the limitation of maximum temperature. Gas welding is suitable for welding in confined locations since it requires only safety glasses (as against safety helmets required for arc welding). Oxygen need not be completely mixed with fuel gas before they leave the tip and create the flame. Hydrogen can be used for underwater welding and cutting. Welding and Cutting Steel Oxy-Acetylene and other methods (3 publications) By John C Bullas. Oxy-acetylene flame may also be used for all types of brazing. The gas welding fumes generated during the welding can be from the work material, filler material, and fluxes. The operator can trigger the level to allow the flow of additional oxygen. The cylinders are fitted with regulators and flexible hoses which lead to the blowpipe. During gas cutting, the metal is heated till it becomes red hot, and at this point, the flow of oxygen is increased by triggering the lever. A neutral flame is chemically neutral. The melting point of the metal oxide is less than the melting point of the metal being cut (50% less). Acetylene – Acetylene is the popular fuel gas used for gas welding and gas cutting. As the flame is less intense than an arc and very little UV is emitted, general-purpose tinted goggles provide sufficient protection. The increased oxygen reacts with the hot metal, makes the metal get oxidized, and produces more heat to help the cutting process. This flame has two parts, a light blue inner cone and a dark blue (fading to colorless) outer cone. When welding, the operator must wear protective clothing and tinted coloured goggles. Control valves control the amount of gas going out of the cylinder, and using the control valves; you can control the ratio of the fuel gas and oxygen mixture.
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